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Zero helium consumption
Monitoring without removing helium from the system (helium recovery monitoring). MSLDs and sniffer sensors lose gas with every measurement – in closed recovery loops, that means direct losses.
Helium Leak Detector
Inline TCD-based He detection with zero gas loss. Built for helium recovery systems, fiber-optics manufacturing, cryogenic plants and leak-test benches.
The industrial helium leak detector by Archigas is a device for continuous measurement of helium concentration in gas streams. It solves three problems: monitoring equipment tightness, localizing leaks, and tracking the performance of closed-loop He recovery. The inline solution from Archigas GmbH based on TCD technology delivers a signal in 30 ms, remains operational at pressures up to 200 bar, and consumes virtually no helium during measurement.
Certifications & Standards
Archigas products confirm their reliability, quality, and safety with valid certificates.
ATEX Zone 1 (II 2 G Ex db IIC T4/T3 Gb, -40°C to +90°C/+125°C)
Certification for use in potentially explosive atmospheres
IECEx
International conformity certificate for explosive atmospheres
UL HazLoc
Certification for USA (hazardous locations)
CE
Compliance with European Union requirements
ISO 9001:2015
Certified quality management system
Why clients choose Archigas for helium monitoring
8+
global distribution partners
25+
customer countries reached
125+
B2B and industrial companies served
400+
customer projects supplied
How a TCD helium leak detector works
The TCD detector measures helium concentration in a gas mixture by detecting the difference in thermal conductivity between the measured gas and the carrier gas without any sample extraction or venting of gas from the process line.
Helium has substantially higher thermal conductivity than most carrier gases – nitrogen, argon, and others. As He concentration in the stream changes, the sensor registers a temperature shift.
The sensor is mounted directly in the process pipeline. Helium stays in the system; no additional maintenance of a sampling infrastructure is required.
The output signal, 4–20 mA or Modbus RTU, is transmitted directly to the control system or automation platform.
Industrial helium leak detector solutions by Archigas
Industrial helium leak detector solutions by Archigas come in two configurations: TCD3000 Si and TCD3000 SiA.
Both versions operate on the same principle and serve the same purpose: monitoring He content without a bypass and without gas loss during measurement. The difference lies in installation zone requirements and applicable certifications.
TCD3000 Si
Suitable for standard industrial environments requiring continuous inline helium monitoring.
TCD3000 SiA
Designed for hazardous areas and projects with elevated certification requirements.
Parameter | TCD3000 Si | TCD3000 SiA |
|---|---|---|
Installation zone | Standard industrial environments | Potentially explosive atmospheres |
Certification | CE, UL, ISO 9001:2015 | ATEX (II 2 G Ex db IIC T4/T3 Gb), IECEx, CE, UL |
Ambient temperature | −40 °C to +80 °C | −40 °C to +90 °C / +120 °C |
Dimensions (with connectors) | H: 91 mm; Ø: 45 mm | H: 96 mm; Ø: 45 mm |
Weight | 440 g | 740 g |
Parameter | Value |
|---|---|
Measurement principle | TCD (Thermal Conductivity Detector) |
Measurement range | From a few ppm to 100 vol.% He |
Reaction time | 30 ms |
Process gas pressure | 0.9–200 barg |
Process gas temperature | −40 °C to +90 °C / +125 °C |
Measured value drift | |
Output signal | 4–20 mA / RS485, Modbus RTU |
Recalibration interval | 6 months |
Service life | Up to 10 years |
Manufactured | Made in Germany, Rüsselsheim |
How quickly will the TCD3000 leak monitoring system pay for itself at your facility?
5 crises since 2006
Market remains volatile
>400%
Price growth over recent years
14 factories
worldwide
Engaged in helium liquefaction
~$15,000/ year
Losses from a 1 L/min leak, 24/7
3–14
months
months
Typical payback period for an Archigas inline detector
Find out how much helium your system is losing — and how to fix it. Archigas engineers will assess applicability for your specific process.
Request a process assessmentWhere helium leak detection matters most
Helium Leak Detection TCD vs. other Methods for helium leak detection
There are three main approaches to helium leak detection in industrial settings: TCD inline analyzers for continuous concentration monitoring, mass spectrometer leak detectors (MSLD) for high-sensitivity tightness testing, and sniffer probes for localizing point leaks. Each method has a distinct role, not a competing one.
Method | Typical use case | Sensitivity | Continuous monitoring? | He consumption |
|---|---|---|---|---|
TCD inline (Archigas TCD3000 SiA / TCD3000 Si) | He recovery loops, purity monitoring, leak-test bench supply control | ppm-level → 100 vol.% | Yes, 24/7 real-time | Zero (inline, no sampling) |
Mass spectrometer (MSLD) | Tightness testing of finished parts (HVAC, automotive components) | 10⁻¹² mbarg·L/s | No, periodic batch testing | Moderate (vacuum chamber) |
Sniffer probe | Manual localization of point leaks | 10⁻⁶ mbarg·L/s | No, operator-driven | High (gas escapes during sniffing) |
TCD3000 Si and TCD3000 SiA operate 24/7 in recovery loops and process control applications, where periodic batch testing is not feasible. For building a helium leak monitoring system or optimizing helium consumption, an inline TCD detector is the technically justified choice for those seeking an alternative to mass spectrometer solutions.
Clients and Partners
Why TCD3000 SiA and TCD3000 Si for helium applications
Prof. Dr. rer. Nat. habil. Friedemann Völklein
RheinMain University of Applied Sciences
Chief Scientific Advisor and Design Development
Chief Scientific Advisor and Design Development
“Most of our customers come to us after they’ve calculated how much helium they’re losing to micro-leaks. An MSLD is excellent for final acceptance testing of the final part, but it’s useless for 24/7 operation. The TCD3000 Si fills exactly that gap, continuous monitoring in recovery lines where every hundredth of a percent in concentration has a price. And no gas sampling, otherwise the whole point of saving helium is lost.”
Integration into helium recovery and leak-test systems
TCD3000 Si and TCD3000 SiA are mounted directly in the process pipeline with no sample line or ancillary equipment. The output signal connects directly to a PLC or control system. Three typical configurations are described below.
FAQ
What is a helium leak detector?
A helium leak detector is an instrument that identifies leaks in pressurized or vacuum systems by detecting helium gas, used either as a tracer gas or as the working medium itself. Industrial helium leak detectors range from mass spectrometer–based MSLDs for tightness testing to inline TCD analyzers, such as the Archigas TCD3000 Si, for continuous concentration monitoring in helium recovery systems.
How does a helium leak detector work?
The operating principle depends on the technology used:
- A TCD detector measures the change in thermal conductivity of the gas mixture as the helium concentration changes, without sample extraction or venting gas from the process line.
- MSLD systems ionize gas inside a vacuum chamber and separate ions by mass.
- Sniffer detectors register localized increases in helium concentration at the surface of the test object.
What is the difference between TCD and mass spectrometer helium leak detectors?
A TCD analyzer and a mass spectrometer detector serve different purposes and are applied at different stages. The TCD analyzer is designed for continuous inline monitoring of helium concentration in a process line, where constant monitoring under working pressure without process interruption is required. The mass spectrometer detector delivers sensitivity down to 10⁻¹² mbar·L/s and is used for periodic testing of finished parts. Where the task is monitoring a recovery loop or a process line 24/7, TCD is the technically justified choice.
Do I need an ATEX-certified helium leak detection system?
ATEX certification is not required for most industrial applications – helium is inert and does not create an explosive atmosphere. If helium is used alongside flammable gases, or if the installation zone is classified as hazardous for other reasons, the TCD3000 SiA model applies and is certified for ATEX Zone 1 and IECEx.
How often should a helium leak detector be calibrated?
TCD3000 Si and TCD3000 SiA are recalibrated every 6 months. Initial calibration is performed at the Archigas factory in Germany, tailored to the specific gas mixture and process conditions. Field recalibration is carried out by the user without stopping the process.
How quickly can a helium leak detector pay for itself in a recovery system?
The typical payback period for an inline helium detector ranges from 3 to 14 months, depending on consumption volume: for large consumers (above 30,000 m³/year) – 3–4 months; for smaller volumes – 6–14 months. Actual figures are calculated individually based on process data.
Can the TCD3000 Si and TCD3000 SiA measure helium in any background gas?
The TCD method is optimal for binary and quasi-binary mixtures in which helium is the only light component against a heavy carrier gas – nitrogen, argon, or air. If the mixture contains other light components, such as hydrogen, an additional applicability assessment is required. Configuration for a specific gas composition is performed at the Archigas factory prior to delivery.
Talk to an application engineer
Describe your process parameters – helium flow rate, working pressure, and system requirements. Archigas engineers will select the right TCD helium leak detector configuration and respond within one business day.
Tom Burkard
Archigas engineer
